1. Management Meeting Month X, 20XX
Lean in Action 5S System: Techniques for Efficient Workplace Organization
Management Meeting
Month X, 20XX

2. What is 5S? A visual method of workplace organization 5S helps to:
Have needed material, tools, supplies, and documentation at hand, organized, and identified
Maintain a clean work area with tools and equipment in top condition
Standardize workplace organization
Maintain a occupationally-safe, ESD-safe, FOD-free workplace

3. In short, an organized workspace
Why employ 5S?
An organized, clean workplace:
Shortens Span Times
Reduces the non-value added work of searching for materials, tools, equipment and paperwork
Reduces Floor Space requirements
Prevents and detects errors and defects
Raises team pride and job satisfaction
Makes work easier to accomplish
In short, an organized workspace
enhances safety
improves quality
and reduces cost and cycle time

4. Elements of a 5S Program
Sort
Set in Order
Shine
Standardize
Sustain

5. 5S - Down to Basics
SORT
Remove all
non-essential
items from
around the
work area.
Any essential
items that do
not fit or work,
or are broken,
are tagged
for action.
SET IN ORDER
A place for
everything
and
in its place.
Arrange items
so they can
be found,
retrieved
and returned
easily.
SHINE
Remove dust,
dirt & debris.
Cleaning will
also highlight
any previously
unforeseen
problems.
Prioritize
safety, quality
and reliability
issues.
STANDARDIZE
Spread
through the
work place.
Checklists are
made showing
exactly where
and when
regular
maintenance
should take
place.
SUSTAIN
Everyone
who uses the
work area is
encouraged
to adopt the
new system.
Eventually
the new
arrangements
will become
the culture.
For 5S to be effective, everyone must take full responsibility for their own area of work, while supporting 5S throughout the shared workplace

6. Elements of a 5S Program Sort Set in Order Shine Standardize Sustain
Eliminate the clutter
“When in Doubt, Throw It Out!”
Create a place for everything and put everything in its place
Arrange needed items so that they are easy to use and label them so that “anyone” can find them and put them away
Use Visual Aids to aid understanding and minimize complexity
Shadow Boards
Labels (“Return addresses”)
Clearly marked places for items that are movable
Area Identification signs
Lines on the floor
Set in Order
Shine
Standardize
Sustain

7. Sort: Workstations
What work
is being
Performed?

8. Sort: Workstations
Before
After

9. Sort: 5S Holding Area
If unsure whether or not to discard an item, a 5S Holding Area should be established
Items should remain in the area for a short period of time, reassessed, and either discarded or (if needed) placed back into the work area
All items should have a 5S Holding Tag for identification (next slide)
Items will be logged in a database and tracked

10. Sort: 5S Holding Tag (example)
Tag is used for tracking and maintaining items that are in the 5S Holding area that are to be reevaluated for either disposal or for placement back into appropriate area
5S Holding Tag should be filled out completely and logged into database
Date placed in Holding Area
Individual that tagged the item
Area item came from (stock, assembly, Test area etc.)
Short description (include P/Ns if necessary)
Reason why in Holding Area (obsolete, not needed, broken, etc.)
Proposed next steps to take
Used to track all items
example

11. Elements of a 5S Program Sort Set in Order
Organize and label, set boundaries and limits
“A Place for Everything and Everything in its Place”
Why: Makes things easy to locate, easy to put away, readily apparent if missing
Results: No wasted time looking for tools or documents; they are identified and on hand when needed
One-Step Rule: Nothing that is used daily is stored more than a step away. Improve economy of motion, save valuable seconds, and make the job less frustrating.
45 Degree Rule: Arrange the immediate work area layout to minimize twisting, especially applicable for bench work. If something weighs more than a few pounds, make sure it is beyond immediate reach so the lifter must reposition the body properly for lifting.
Strike Zone Rule: Store things above the knees and below the chest. This will help to reduce the chance of back strain.
Higher the Pounds - Closer to Knuckles: Locate heavy items to eliminate bending, stooping or unnecessary arm movements during lifting.

12. Set In Order: Tool Crib Before Organization

13. Set In Order: Tool Crib After Organization

14. Set In Order: Unorganized Toolbox

15. Set In Order: Organized Toolbox

16. Elements of a 5S Program Sort Set in Order Shine Standardize Sustain
Clean everything, inside and out
“Inspection Through Cleaning”
Why: Nobody works well around a mess; FOD can ruin or delay a mission; a clean workplace promotes pride and demonstrates an interest in quality; cleaning allows us to find problems with equipment and tools in time to prevent delays
Results: A bright, clean, organized, work area that promotes confidence, quality, and on time delivery
Standardize
Sustain

17. Shine: Before Cleaning

18. Recognize and Reward the Team !!
Shine: After Cleaning
Recognize and Reward the Team !!

19. Elements of a 5S Program Sort Set in Order Shine Standardize Sustain
Document the standard method for workplace organization so we always do things in the same way
“Everything in a State of Readiness”
Why: Standardizing the way we maintain a work area and perform our work promotes consistency in how work is approached and accomplished, and allows easier cross training and movement of personnel
Results: Standardized presentation of work areas, material and tools for work
Sustain

20. Standardize: Best Practices for Organization
Old way
New Standard

21. Standardize: Best Practices for Organization
Old way
New Standard

22. Standardize: Shadow Part Kits

23. Elements of a 5S Program Sort Set in Order Shine Standardize Sustain
Maintain discipline through systems and a supportive culture
“Launching quality with persistence.”
Why: Without sustaining the first 4 Ss, they will die; promotes a continuous improvement environment
Results: Ever improving quality, cycle times, on time commitments; high motivation, recognition for excellence

24. Sustain: Teams set Standards to meet Customer Demand
Communications Board in the area shows the Continuous Improvement List, Current Schedules and Metrics
White board is for anyone to post any issue to be put on the Continuous Improvement List

25. Sustain: Teams set Standards to meet Customer Demand – Show progress
Publicity !

26. Sustain: Standard Assessment Score (spider web chart)

27. Getting Started Form 5S Teams: Conduct 5S Kaizen event:
All players who regularly work in the work are/ center
If you use tools, hook up & use test equipment, handle parts, or regularly handle travelers, drawings or Work Procedures in the area, we want you on the team
Conduct 5S Kaizen event:
Learn what a 5S workplace looks like
Only needed things present
Clean; dustless
All things organized, arranged and identified
Visuals help tell at-a-glance the state of the workplace (signs, posters, arrows, charts, schedules, etc.)

28. Getting Started Plan for Success: First Steps: Set team 5S goals
Appoint 5S champion(s)
First Steps:
Post 5S team roster with leader, champions, and backups for calibration, shelf life, job supplies
Create a 5S holding area
Sort unneeded items and move them to the 5S holding area
Conduct monthly 5S Assessments
Using Standard 5S Assessment

29. Monthly 5S Scoring
-- example only --

30. What Level is Your Work Area?
Levels of Achievement
What Level is Your Work Area?
SORT
SET IN ORDER
SHINE
STANDARDIZE
SUSTAIN
LEVEL 1
Just Beginning
Necessary and
unnecessary items are
mixed together in the
work area.
Tools, supplies and
materials are randomly
located.
Work/break areas and
machinery are dirty and
disorganized.
Work place methods are not
consistently followed and are
not documented.
Work place checks are
randomly performed and
there is no visual
measurement of 5S
performance.
LEVEL 2
Focus on Basics
separated.
Designated location
established for all items
as needed.
machinery are cleaned on
a regularly scheduled
basis. Key items
identified.
Methods are being improved,
but changes have not been
documented.
A recognizable effort has
been made to improve the
condition of the
workplace.
LEVEL 3
Make It Visual
All unnecessary items
have been removed
from the work area.
Designated locations are
marked to make
organization more visible
(color, outlines, labels,
numbers, etc).
Visual Controls are in
place for labeling and
quantity levels. Machines
are cleaned daily.
Working environment changes
are documented and
performed the same by all
employees. Visual Controls are
in place for labeling and
quantity levels.
5S schedules and safety
practices have been
developed and are
utilized.
LEVEL 4
Focus On
Consistency
A dependable,
documented method
has been established to
keep the work area free
of unnecessary items.
Documented method of
visual sweep to identify
items out of place or
exceeding quantity
limits.
5S techniques are
understood and practiced
continually. 5S schedules
are posted and followed.
Substantial process
documentation is available and
followed.
Follow through with 5S
schedules and safety
practices is evident.
LEVEL 5
Focus on
Prevention
Waste is immediately
visible and triggers a
planned response with
root cause analysis and
corrective action.
Defined process to
evaluate and improve
movement and motion.
Dependable, documented
method of preventative
cleaning and
maintenance.
Everyone is continually seeking
the elimination of waste with
changes documented and
information shared.
There is a general
appearance of a confident
understanding of, and
adherence to, the 5S
principles.

31. Let’s Go ! Designate and identify location(s) for cleaning gear
Tape aisle ways and perimeter of work areas
Shadow box all needed tools; hang large tools on outline boards
Sweep/ shine floors; post a cleaning schedule w/ names & assignments
Clean in corners, around I-beams & columns; wipe off wire molds, vents, equipment, cabinets so that there is no dirt, dust, paper clips, loose pens, loose papers, sticky notes, throw away or put away ANYTHING laying around
Remove things from the top of cabinets, consoles, tables, chairs, etc.

32. Let’s Go !
ANYTHING that HAS to be stacked is stacked neatly (90°) in a designated location
Implement visual helps to indicate where things go, including cleaning and safety gear
Conscientiously conduct FOD and ESD surveillance
Perform TPM on equipment
Keep aisles clear; limit extension cords; no tripping or tipping hazards; call attention to safety equipment locations
Visually highlight equipment safety features (emergency stops, stay out areas, etc.)

33. Let’s Go ! Post evacuation routes near exits
ID chemical storage cabinet locations and check frequently
ID and Wear protective equipment
Have MSDS sheets in a clearly marked area
Find a place for EVERYTHING; mark its perimeter and identify it
Maintain the 5S bulletin board
Evidence “clean-as-you-go” throughout the day
Assess the area monthly; discuss and act on results
Post results in 5S display area
Hang posters, signs, etc. to sustain 5S

34. Management Meeting Month X, 20XX
Lean in Action 5S System: Techniques for Efficient Workplace Organization
Management Meeting
Month X, 20XX